Flooring system having microbevels

ABSTRACT

Laminated flooring panels include decorative motifs, mechanically embossed-in-registration surface textures, recessed perimeters, and locking mechanisms. The locking mechanisms facilitate the alignment of adjacent flooring panels. Adjacent flooring panels substantially aligned allow embossed-in-registration patterns to be substantially continuous across adjacent flooring panels. The recessed perimeter prevents the edges of the flooring panel from prematurely wearing. Individual flooring panels within the flooring system may comprise at least one partial sub-panel having a decorative motif and/or embossed surface texture that is complementary with a decorative motif and/or embossed surface texture of a neighboring partial sub-panel.

This application is a divisional of U.S. patent application Ser. No.10/678,219, filed on Oct. 6, 2003, scheduled to issue on Nov. 23, 2010as U.S. Pat. No. 7,836,649, which is a Continuation-in-Part ofco-pending application Ser. No. 10/374,751, filed on Feb. 27, 2003,entitled “FLOORING SYSTEM HAVING COMPLEMENTARY SUB-PANELS”, which is aContinuation-in-Part of application Ser. No. 10/352,248, filed on Jan.28, 2003, entitled “FLOORING SYSTEM HAVING COMPLEMENTARY SUB-PANELS”,scheduled to issue on Nov. 23, 2010 as U.S. Pat. No. 7,836,648, which isa Continuation-in-Part of application Ser. No. 10/137,319, filed on May3, 2002, entitled “EMBOSSED-IN-REGISTER PANEL SYSTEM”_, now U.S. Pat.No. 6,691,480, all of which are hereby incorporated by reference for allpurposes as if fully set forth herein. This application alsoincorporates by reference application, Ser. No. 09/903,807, filed onJul. 31, 2001, entitled “EMBOSSED-IN-REGISTER MANUFACTURING PROCESS”_”,now U.S. Pat. No. 6,638,387 and U.S. Pat. No. 6,401,415, filed on Dec.13, 1999, entitled “DIRECT LAMINATED FLOOR”, for all purposes as iffully set forth herein.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to laminated materials. More particularly,the present invention relates to a flooring system of interlockedlaminated materials having decorative motifs and surface textures thatare mechanically embossed in registration with their decorative motifs.

2. Discussion of the Related Art

Because of their look and feel, traditional building and finishingflooring materials such as fine woods, slate, granite, stones, brick,and concrete are generally preferred by consumers. However, suchtraditional building and finishing flooring materials tend to beexpensive to produce and install. For example, while a solid wood floorhas a highly valued luxurious appearance, the materials and laborrequired to install such floors can be prohibitively expensive.

Many alternatives to traditional building and finishing flooringmaterials are available, including laminates such as high-pressurelaminates (HPL), direct-pressure laminates (DPL), andcontinuous-pressure laminates (CPL). However, such alternativestypically do not possess the realistic look and texture of thetraditional building and finishing flooring materials. For example, mostalternatives having an outer surface with a wood motif look fake and canreadily be identified as something other than authentic wood.Furthermore, while high quality HPL, DPL, and CPL boards may visuallylook like wood, their textures readily reveal that they are not.

One problem with most alternatives to traditional building and finishingflooring materials is that their surface textures do not match theirdecorative motifs. For example, visual depictions of wood knots inalternative flooring materials are not matched with surface texturescharacteristic of the wood knots. Accordingly, the attractiveness ofthese alternative materials is significantly reduced.

One approach used to match the surface texture of alternative flooringmaterials to their decorative motifs includes a technique known aschemical embossing. In chemical embossing, the surface texture of thealternative material is developed by chemically reacting an ink thatforms the decorative motif with an agent added to a sub-surface layer.While somewhat successful, the resulting surface texture tends to lackthe textual sharpness and three-dimensional characteristics oftraditional materials.

As an alternative to the traditional building and finishing flooringmaterials laminated materials may be mechanically embossed to produce asurface texture. See, for example U.S. patent application Ser. No.09/903,807 and U.S. Pat. No. 6,401,415, which are hereby incorporated byreference. Such methods produce embossed-in-registration laminatedmaterials having decorative motifs and matching high-qualitythree-dimensional textures. Embossed-in-registration laminated materialsrequire accurate registration of mechanical embossment and thedecorative motif. An advantage of embossed-in-registration laminatedmaterials is that they can realistically reproduce the look and feel oftraditional products.

No matter what type of flooring system is used, the flooring system mustbe easily moved to a work site while being easy and quick to install. Tothis end, assembly and locking mechanisms may be incorporated withinflooring systems to facilitate on-site installation. One type ofassembly and locking mechanism is the tongue and groove system used forconnecting panels. It is understood that such tongue and groove systemsare disclosed in Cherry, U.S. Pat. No. 2,057,135, and in Urbain, U.S.Pat. No. 2,046,593. For example, FIG. 1 can be interpreted to illustratea tongue and groove system 11 that uses clips 12 to secure panelstogether.

Another type of assembly and locking mechanism is understood to bedisclosed in Chevaux, U.S. Pat. No. 3,946,529 where a flooring system 13appears to be connected using a tongue and groove system arrangedunderneath the flooring, reference FIG. 2.

Still another assembly and locking mechanism is taught in Kajiwara, U.S.Pat. No. 5,295,341. There, it is understood that laminated boards areprovided with a snap-together system such as a groove-tongue joint. As aresult the laminated boards can be assembled without glue. Referring toFIG. 3, the laminated boards are provided with a locking means in theform of a groove connector 16, and a tongue connector 18. The grooveconnector 16 has forwardly protruding grooves 20, while the tongue 18 isprovided with a pair of forwardly diverging sidewalls 22 and 24 that areseparated by an elongated groove 26. The sidewalls include rear lockingsurfaces 28 and 36. The sidewalls can be compressed together to enablelocking.

Another type of assembly and locking mechanism is the snap-togetherjoint is suggested in Märtensson, U.S. Pat. No. 6,101,778. As shown inFIG. 4, it is understood that laminated boards are provided with alocking means comprised of a groove 6 and a tongue 7 that form atongue-groove assembly. The groove 6 and tongue 7 may be made of watertight material and snapped together with a portion 9 fitting in a slot4.

While the aforementioned assembly and locking mechanisms have provenuseful, they have not been used with embossed-in-registration laminatesystems in which embossed-in-registration decorative motifs or graphicsalign across joints between the individual embossed-in-registrationlaminates. This significantly detracts from the visual and texturalimpression of systems comprised of embossed-in-registration laminateboards. Therefore, a new embossed-in-registration laminate system inwhich the visual and textural patterns cross joints while retaining theembossed-in-registration aspects would be beneficial. Even morebeneficial would be an embossed-in-registration laminate systemcomprised of interlocking embossed-in-registration laminate boards inwhich the visual and textural patterns cross joints while retainingembossed-in-registration aspects.

Further, the aforementioned flooring systems have a relatively lowability to resist wear. While not wishing to be bound by any particulartheory, it is hypothesized that premature aging (wear) begins at or nearthe perimeter edges and/or along tongue and groove lines. Theaforementioned flooring systems have a substantially even (level)surface texture such that the center and perimeter of each panel contactusers (e.g., pedestrians) an equal amount. The perimeter of each panel,however, is substantially weaker than the center of the panel andtherefore deteriorates first.

Accordingly, there is a need for a workable method of fabricatingalternative building or finishing materials where the alternatives havethe realistic look and feel of traditional products and have anincreased capacity to resist premature wear.

SUMMARY OF THE INVENTION

Accordingly, the present invention is directed toembossed-in-registration flooring system that substantially obviates oneor more of the problems due to limitations and disadvantages of therelated art.

An advantage of the present invention provides anembossed-in-registration flooring system including individual adjacentflooring panels having embossed-in-registration decorative motifs whereat least one of a surface texture and decorative motif is substantiallyaligned between adjacent flooring panels.

Another advantage of the present invention provides anembossed-in-registration flooring system including interlocked flooringpanels having embossed-in-registration decorative motifs where at leastone of a surface texture and decorative motif is substantially alignedbetween adjacent flooring panels such that substantially continuousembossed-in-registration patterns are formed across the interlockedflooring panels.

Another advantage of the present invention provides anembossed-in-registration flooring system may, for example, includeflooring panels wherein a surface of a perimeter of each individualflooring panel may be recessed such that an upper surface of theperimeter of the flooring panels is below a portion of an upper surfaceof the flooring panels surrounded by the perimeter.

Additional features and advantages of the invention will be set forth inthe description which follows, and in part will be apparent from thedescription, or may be learned by practice of the invention. These andother advantages of the invention will be realized and attained by thestructure particularly pointed out in the written description and claimshereof as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are exemplary and explanatory and areintended to provide further explanation of the invention as claimed.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide a furtherunderstanding of the invention and are incorporated in and constitute apart of this specification, illustrate embodiments of the invention andtogether with the description serve to explain the principles of theinvention.

In the drawings:

FIG. 1 illustrates a related art assembly and locking mechanism;

FIG. 2 illustrates another related art assembly and locking mechanism;

FIG. 3 illustrates yet another related art assembly and lockingmechanism;

FIG. 4 illustrates still another related art assembly and lockingmechanism;

FIG. 5 illustrates a perspective view of components in anembossed-in-registration flooring panel according to the principles ofthe present invention;

FIG. 6 illustrates a press machine capable of fabricatingembossed-in-registration flooring panels in accordance with theprinciples of the present invention;

FIG. 7 illustrates an embossed-in-registration flooring panel in oneaspect of the present invention;

FIG. 8 illustrates a top view of a system of embossed-in-registrationflooring panels in another aspect of the present invention;

FIG. 9 illustrates a cross-sectional view along line 9-9 shown in FIG.8;

FIG. 10 illustrates a top view of a system of embossed-in-registrationflooring panels in yet another aspect of the present invention;

FIG. 11 illustrates a cross-sectional view along line 11-11 shown inFIG. 10;

FIGS. 12A and 12B illustrate schematic views including a perimetersurface portion of a flooring panel in accordance with the principles ofthe present invention;

FIGS. 13A and 13B illustrate a flooring system in still another aspectof the present invention; and

FIG. 13C is a three-dimensional perspective view of the aspect ofexemplary embodiment of the invention illustrated in FIG. 13B;

FIGS. 14A-14C illustrate an exemplary plank of a flooring system instill another aspect of the present invention.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Reference will now be made in detail to embodiments of the presentinvention, examples of which are illustrated in the accompanyingdrawings.

Turn now to FIG. 5 for a depiction of components of a direct pressurelaminate product. Such products are typically fabricated from a baseboard 34, beneficially a medium or high density fiberboard or chipboard.One or more kraft paper sheets 36 (for clarity, FIG. 5 shows only onekraft paper sheet) impregnated with selected resins are located onand/or under the base board 34. A decorative cellulose paper sheet 38,about 0.15 mm thick and impregnated with a melamine solution, is on thebase board 34. Over the decorative cellulose paper sheet 38 are one ormore protective overlay sheets 30. The protective overlay sheet(s) aremade of a highly resistant paper having corundum (AL₂O₃) impregnated ina melamine solution. It is also possible to include different papersbetween the decorative cellulose paper sheet and the base board.

The structure of FIG. 5 is then pressed under heat (180-220° C.) andpressure (approximately 20-30 Kg/cm²) until the resins thermoset. Theresult is an extremely hard and permanent product.

FIG. 6 generally illustrates components of a flooring panel according tothe principles of the present invention.

Referring to FIG. 6, an embossed-in-registration flooring system may,for example, include at least one flooring panel. In one aspect of thepresent invention each flooring panel may include a board substrate 40made out of a substrate material (e.g., a medium or high densityfiberboard, chipboard, etc.), at least one base sheet 48 (e.g., a kraftpaper sheet) impregnated with predetermined resins and arranged overand/or under the board substrate 40, a decorative paper sheet 44 about0.15 mm thick and impregnated with a polymerizable resin (e.g., phenolssuch as melamine) arranged over the board substrate, and at least oneprotective overlay sheet 46 arranged over the decorative paper sheet 44.In one aspect of the present invention, each protective overlay sheet 46may be formed from a highly resistant paper impregnated with a melaminesolution containing corundum (Al₂O₃), silica, etc. In another aspect ofthe present invention, different papers may be arranged between thedecorative paper sheet 44 and the board substrate 40. In one aspect ofthe present invention, the at least one protective overlay sheet 46 andthe base sheet 48 may be impregnated with a resin. In another aspect ofthe present invention the resin impregnating the at least one protectiveoverlay sheet 46 and the base sheet 48 may be different from themelamine resin used to impregnate the decorative paper sheet 44.

In one aspect of the present invention, flooring panels within aflooring system may be fabricated from substantially the same paper,resin, etc. For example, flooring panels within a flooring system may befabricated using paper made from substantially the same paper fibers(having, for example, substantially the same ash content, color, andorientation) on the same on the same paper making machine. Further,flooring panels within a flooring system may be fabricated using paperoriginating from a single, contiguous section on the manufacturingspool. All of the aforementioned paper use restrictions that may beemployed in fabricating flooring panels of a flooring system ensure thatimpregnated papers will always have substantially the same finaldimensions after they are pressed and cured.

In one aspect of the present invention, the warehousing of paper used tofabricated flooring panels within a flooring system may be controlledsuch that the time, temperature, and humidity in which the paper isstored is maintained to facilitate consistent flooring panel dimensions.In another aspect of the present invention, flooring panels within aflooring system may be fabricated using cellulose paste made from thesame manufacturer. In yet another aspect of the present invention,flooring panels within a flooring system may be fabricated using resinsmade from the same manufacturer. In still another aspect of the presentinvention, the resins may contain powder originating from substantiallythe same source, have substantially the same chemical and physicalqualities, and be mixed in the same reactor. Further, flooring panelswithin a flooring system may be fabricated using resins have asubstantially constant solids content. All of the aforementioned resinuse restrictions that may be employed in fabricating the flooring panelsensure that impregnated papers will always have substantially the samefinal dimensions after they are pressed and cured. In still anotheraspect of the present invention, each of the flooring panels within aflooring system may be fabricated using substantially the sameimpregnation process. For example, when dipping the various sheets ofpaper into melamine resin, the paper should experience a constant,uniform melamine load. Further, a band tension and oscillation of theimpregnation machine should be precisely controlled as they influencethe degree to which the various paper sheets are impregnated with theresin.

According to the principles of the present invention, the aforementionedsheets and substrates may be fabricated into an embossed-in-registrationflooring system including a plurality of interlocking flooring panels.To produce such a flooring system, a press machine, such as a pressmachine shown in FIG. 6, may be used to mechanically emboss eachflooring panel in registration with a decorative motif arranged on thedecorative paper sheet 44.

Referring to FIG. 6, the press machine may, for example, include a base42, a top press 54, and an upper press plate 56. In one aspect of thepresent invention, the upper press plate may include an embossingpattern (e.g., a three-dimensionally textured surface). Accordingly, theembossing pattern may, for example, include elevated ridges, dots,depressions, etc., of any design capable of being aligned with adecorative motif formed on the decorative paper sheet 44.

According to the principles of the present invention, the impregnateddecorative paper sheet 44 arranged on the board substrate 40 must beaccurately positioned relative to the embossing pattern of the upperpress plate to enable an embossed-in-registration flooring panel. In oneaspect of the present invention, alignment between the embossing patternof the press plate and the decorative motif must be ensured when thepress is in a locked position and the board is under pressure. Thedegree of control required may vary depending on the type of decorativemotif used. For example, alignment of a wood grainembossed-in-registration motif across adjacent embossed-in-registrationflooring panels requires a higher degree of alignment than alignment ofa wood grain embossed-in-registration motif that is not aligned withadjacent flooring panels.

Alignment between the decorative motif on the decorative paper sheet 44and the embossing pattern on the upper press plate 56 may be achieved byremoving about 2 to 3 millimeters of material around the perimeter ofthe board substrate 40 in a milling process thereby yielding severalreference planes (e.g., board edges) and a board substrate havingtightly controlled dimensions. Next, an impregnated decorative papersheet 44 having exterior dimensions about 8 or 10 mm smaller than theboard substrate 40 is arranged on the board substrate 40. In one aspectof the present invention, the impregnated decorative paper sheet 44 maybe arranged on the board substrate 40 using the board edges as alignmentmeans. In one aspect of the present invention, alignment marks may bearranged on the board substrate 40 and be alignable with alignment marksprovided on the decorative paper sheet 44.

In one aspect of the present invention, the decorative paper sheet 44may be attached to the board substrate 40 via static electricity. Afterthey are attached, the decorative paper sheet 44 and the board substrate40 are arranged on a carriage feeding into the press machine. The staticelectricity may substantially prevent the decorative paper sheet 44 frombeing accidentally displaced as the board substrate 40 is moved with thecarriage. In one aspect of the present invention, the carriage may bestopped just before it enters into the press machine such that thedecorative paper sheet 44 may be precisely arranged over the boardsubstrate 40 using, for example, tweezers (not shown). In another aspectof the present invention, the tweezers may be used to precisely arrangethe decorative paper sheet 44 over the board substrate 40 arranged onthe lower press plate. In one aspect of the present invention, thedecorative paper sheet 44, the at least one protective overlay sheet 46,and the optional base sheet 48 may be arranged over the board substrate40 prior to being arranged within the press machine. After thedecorative paper sheet 44 is arranged over the board substrate 40, thecarriage may be moved out of the press machine. Next, an alignmentsystem substantially aligns the decorative paper sheet 44/boardsubstrate 40 system with the embossing pattern in the upper press plate56. In one aspect of the present invention, the alignment system may usethe board edges to substantially align the decorative motif 44 with theembossing pattern on the upper press plate 56. The press machine may beoperated after the alignment is complete.

In one aspect of the present invention, after the components illustratedin FIG. 5 are arranged within the press machine and aligned with theembossing pattern, the various sheets and substrate may be pressed andcured for predetermined amount of time until the resins set, yielding anextremely hard and wear resistant flooring panel. For example, afterbeing inserted into the press machine and aligned with the embossingpattern, the board substrate 40, decorative paper sheet 44, protectiveoverlay sheet 46, and optional base sheet 48 may be heated at atemperature of about 160-220° C. and pressed together under a pressureof about 20-40 Kg/cm² for about 20 to 60 seconds. Accordingly, the toppress 54 presses the embossing pattern of the upper press plate 56 intothe decorative paper sheet 44 and board substrate 40 structure. Thecombination of the applied heat and pressure fuses the decorative papersheet 44 and the board substrate 40 together. The alignment systemensures that the decorative paper sheet 44 is substantially aligned withthe embossing pattern in the upper press plate 56. Accordingly, melamineresin within the various sheets may be cured and anembossed-in-registration panel may be produced.

In one aspect of the present invention, porosity within the fused piecemay be minimized by slowly curing the resins (e.g., the melamine).Accordingly, as the operating temperature is reduced, the time duringwhich the various sheets within the press machine are pressed isincreased. In another aspect of the present invention, as the pressplate 56 is heated to about 160-220° C. the embossing pattern includedwithin the press plate may expand. Accordingly, the embossing pattern onthe press plate 56 may be provided so as to compensate for the expansionof the pattern. Therefore, the dimensions of the embossing pattern areprovided such that they substantially correspond to the design of thedecorative motif when the resins within the components of FIG. 5 arecured.

According to the principles of the present invention, a mechanicallyembossed surface texture may be imparted to an individual flooring panelhaving a decorative motif. In one aspect of the present invention, themechanically embossed surface texture may be provided in registrationwith the decorative motif. Accordingly, an embossed-in-registrationflooring panel may be fabricated. In another aspect of the presentinvention, a plurality of embossed-in-registration flooring panels maybe joined together to form an embossed-in-registration flooring system.In yet another aspect of the present invention, at least a portion ofembossed-in-registration patterns of adjacent flooring panels may besubstantially aligned with each other to form substantially contiguousembossed-in-registration patterns across adjacent flooring panels withinthe flooring system.

While the embossed-in-registration process described above is suitablefor embossed surface textures that are less than about 0.2 mm deep,deeper surface textures may be problematic. Embossing patterns capableof imparting deep surface textures, for example, require relativelylarge press plate protrusions that tend to disturb the pressurehomogeneity applied across the board surface. This pressure disturbancecan cause distortions in the final product. In one aspect of the presentinvention, embossed surface textures may be formed greater than about0.2 mm deep by hollowing out the board substrate 40 at locations wheredeep surface textures are desired. In one aspect of the presentinvention, the hollowing out process may be performed before, during, orafter the perimeter of the board substrate 40 is milled as describedabove. In another aspect of the present invention, the board edges maybe used to locate the boundaries of the hollowed out portions of theboard substrate 40.

Referring to FIG. 7, an embossed-in-registration flooring panel 60,fabricated according to the process described above may optionallyinclude a protective padding layer 50 on one side. The mechanicallyembossed surface texture is registered with the decorative motif 68 ofthe decorative paper sheet 44. By registration, it is meant that theembossed surface texture is substantially aligned with the decorativemotif of the decorative paper sheet 44. By providing anembossed-in-registration flooring panel, a realistic representation of anatural material may provided to individual flooring panels. While thedecorative motif illustrated in FIG. 7 realistically represents theimage and texture of a wood grain, it should be appreciated that otherembossed-in-registration designs such as ceramic planks, concrete,marble, etc., may be produced.

According to the principles of the present invention, each of theindividual flooring panels may, for example, include at least onelocking mechanism.

In one aspect of the present invention, locking mechanisms may beincorporated within the board substrate 40 before the embossing patternis imparted to the surface of the board substrate 40 in registrationwith the decorative motif. Accordingly, locking mechanisms may befabricated within individual board substrates 40. Next, the lockingmechanisms may be used to join individual board substrates together toform a panel structure. The panel structure may then be inserted intothe press 54. After the embossing pattern is imparted to the panelstructure and the fused components are fused together, the panelstructure is removed from the press 54. Next, embossed-in-registrationflooring panels 60 within the fused panel structure are separated byunlocking the locking mechanisms. In one aspect of the presentinvention, cutting tools may be used to assist in the separation and toensure the decorative motif is not damaged.

In another aspect of the present invention, the locking mechanisms maybe incorporated within the board substrate 40 after the embossingpattern is imparted to the surface of the board substrate 40 inregistration with the decorative motif. Accordingly, a board substrate40 having relatively large dimensions of, for example, 4′×8′, may beembossed by the press 54. Next, the resulting embossed-in-registrationsubstrate may be cut into a plurality of individualembossed-in-registration flooring panels 60. In one aspect of thepresent invention, edges of the individual embossed-in-registrationflooring panels 60 may have smooth edges and precise dimensions. In oneaspect of the present invention, the cutting may be performed usingshaping tools, milling tools, cutting tools, breaking tools, etc. In oneaspect of the present invention, the board substrate may be cut by thepress machine. Accordingly, the board substrate 40 may be cut into units(e.g., strips) having dimensions of, for example, 300×300 mm, 400×400mm, 600×600 mm, 1,200×300 mm, 1,200×400 mm, etc. Next, the lockingmechanisms may be incorporated within the individualembossed-in-registration flooring panels 60. In one aspect of thepresent invention, the locking mechanisms may be hidden beneath thesurface of the flooring panels or they may be visible.

According to the principles of the present invention, the lockingmechanisms may be incorporated within the individualembossed-in-registration flooring panels 60 by aligning the at least oneof the board edges, alignment marks, decorative motifs, and surfacetextures of the flooring panel with a milling tool. By aligning themilling tool with any of the aforementioned alignable features, lockingmechanisms may be milled into the sides of the board substrates 40 suchthat, when flooring panels 60 are joined together the at least a portionof the decorative motifs form a continuous pattern and at least aportion of the embossed-in-registration patterns form a substantiallycontinuous surface texture across adjacent flooring panels.

According to the principles of the present invention, theembossed-in-registration flooring panel 60 may include a lockingmechanism 64 (e.g., at least one of a tongue and groove locking system,a snap-together locking system, etc.) extending along all four sides ofthe embossed-in-registration laminate 60. For example, a snap-togetherlocking system may be added to all four sides of theembossed-in-registration flooring panel 60 and used to connect multipleembossed-in-registration flooring panels 60 into anembossed-in-registration flooring system 300 (as shown in FIG. 8). Thenumber and location of locking mechanisms may depend on the desiredconfiguration of the embossed-in-registration flooring system. Forexample, when an embossed-in-registration flooring system abuts acorner, only two locking mechanisms are required (along the sides).

Referring to FIG. 8, the embossed-in-registration flooring panels A andB may, for example, include locking mechanisms along four sides (e.g.,along joints J1, J2, J3, and J4). Embossed-in-registration flooringpanels C and D may, for example, include locking mechanisms along foursides (e.g., along joints J1, J2, J3, and another joint not shown).

Embossed-in-registration flooring panels including the aforementionedlocking mechanisms may be securely attached together with or withoutglue to form an embossed-in-registration laminate system 300. Multipleembossed-in-registration flooring panels may be joined together toobtain any desired shape for flooring, paneling, or the like. Theembossed-in-registration flooring panels may be joined to each othersuch that at least portions of embossed-in-registration patterns ofadjacent flooring panels are substantially aligned with each other andform a substantially continuous image and embossed surface textureacross flooring panels within a flooring system.

FIGS. 8 and 9 illustrate an exemplary embossed-in-registration flooringsystem 300 incorporating one type of locking mechanism on each of theindividual embossed-in-registration flooring panels 60. FIG. 9illustrates an exemplary embossed-in-registration flooring systemincluding flooring panels incorporating a snap-type tongue and groovelocking mechanism. In one aspect of the present invention, the snap-typetongue and groove locking mechanism may be integrated into the sidewallsof each embossed-in-registration laminate 60 so as to ensure thatembossed-in-registration patterns of adjacent flooring panels aresubstantially aligned with each other and substantially continuouswithin the flooring system.

FIG. 9 illustrates a cross sectional view of FIG. 8 taken along line9-9. As shown, the locking mechanism may be fabricated by forming agroove 230, a tongue 200, a channel 210, and a lip 220 along the edgesof the embossed-in-registration flooring panels 60. The lockingmechanisms on the embossed-in-registration flooring panels 60 may bejoined together by inserting the tongue 200 into the groove 230 of anadjacent embossed-in-registration flooring panel 60. Subsequently, thelip 220 is secured within channel 210, thereby joining adjacentembossed-in-registration flooring panels 60 into anembossed-in-registration flooring system 300. In one aspect of thepresent invention, the embossed-in-registration flooring panels 60labeled A, B, C and D may be joined together with or without glue. Itshould is appreciated that other types of locking mechanisms may beincorporated within the sides of the individual embossed-in-registrationflooring panels 60.

Referring back to FIG. 8, each of the embossed-in-registration flooringpanels 60 may, for example, exhibit an embossed-in-registration ceramicplank motif G1. The ceramic plank motif 100 may comprise a plurality ofplanks in the shape of squares, rectangles, triangles, circles, ovals,any other shape or design that are separated by grout lines. In oneaspect of the present invention, widths of grout lines Wh, Wv(illustrated at 150 in FIG. 9), and the intraboard grout width W may besubstantially equal. When incorporating the snap-type tongue and groovelocking mechanism into the embossed-in-registration flooring panels 60the grout width adjacent the joints J1, J2, J3, and J4 on eachembossed-in-registration laminate A, B, C, and D are approximatelyone-half the intraboard grout width W. For example, the vertical plankgrout width (Wv, illustrated at 150 in FIG. 9) across joint J1 is madeup of grout lines on embossed-in-registration laminates A, B, C and D,such that when the embossed-in-registration laminates A, B, C, and D arejoined at J1 the vertical grout width (Wv) is approximately equal to(W). Accordingly, the grout width on any individualembossed-in-registration flooring panel 60 adjacent a joint is one-halfof intraboard grout width (W). In another aspect of the presentinvention, the horizontal and vertical grout widths Wh and Wv may becontrolled such they are substantially equal to the dimensions of theintraboard grout width W. It should be appreciated, however, that thedimensions of the grout widths in the embossed-in-registration flooringpanels depend on the type of locking mechanism incorporated and thedecorative motif exhibited.

In addition to grout lines, many other decorative motifs may be used inthe embossed-in-registration flooring system of the present invention.Referring to FIGS. 10 and 11, a decorative motif exhibiting, forexample, a wood grain surface G2 substantially aligned across joints J5and J6 of adjacent flooring panels may be provided. According to theprinciples of the present invention, wood grain patterns generallyinclude more elements (e.g., wood grain lines, wood knot 423, etc.) thatextend to the perimeters of the flooring panels that need to be alignedthan ceramic plank motifs. Accordingly, aligning the wood grain motif isgenerally more difficult than aligning grout line portions of theceramic plank motifs. For example, aligning a first portion of a woodknot 423 on embossed-in-registration flooring panel E with a secondportion of the wood knot 423 on embossed-in-registration flooring panelF is generally more complex than aligning grout line widths acrossjoints of adjacent flooring panels. Accordingly, when fabricating alocking mechanism, consideration of all the graphic elements (e.g., woodgrains lines and wood knots 423) must be considered to ensure arealistic embossed-in-registration flooring system 400. In one aspect ofthe present invention, at least one portion of the decorative motif maybe used as an alignment marks ensuring consistent alignment of adjacentflooring panels.

In another aspect of the present invention, individual flooring panelswithin the embossed-in-registration flooring system 400 may be joinedtogether with a snap-type mechanical system as illustrated in FIG. 11depicting a cross sectional view of FIG. 10 along line 11-11. Again,alignment techniques used in the fabrication of the locking mechanismsuch that the embossed-in-registration laminate system 400 has a surfacetexture surface 425 that is substantially continuous across joints, J5and J6. Optionally, the embossed-in-registration laminates 60 have aprotective padding layer 70 under the base sheet 48.

FIGS. 12A and 12B illustrate schematic views of a flooring panel inaccordance with the principles of the present invention.

Referring to FIGS. 12A and 12B, an upper surface at the perimeter, P, ofeach embossed-in-registration flooring panel may be recessed below anupper surface at the portions of the flooring panel surrounded by theperimeter. An object O (e.g., a users shoe, a wheel, etc.) contactingthe major surface, Ms, of a flooring panel does not generally contactthe surface of the perimeter, Ps, due to the perimeter's recessedsurface. In one aspect of the present invention, the perimeter mayinclude a portion of the flooring panel extending from the edge of theflooring panel approximately 3.175 mm toward the center of the flooringpanel. In another aspect of the present invention, the depth to whichthe surface of the perimeter of the flooring panel is recessed isapproximately 0.794 mm. In another aspect of the present invention, thesurface of at least one portion of the perimeter of a flooring panel maynot be recessed, as will be discussed in greater detail below withreference to FIG. 13.

Accordingly, the embossed-in-registration pattern may be provided to theedges of the flooring panel and may be aligned withembossed-in-registration patterns formed on adjacent flooring panelswhile the edges of each individual flooring panel may be prevented fromprematurely wearing.

Although it has been shown in FIGS. 8 and 10 that individual flooringpanels within a flooring system are substantially the same size andshape and are joined to each other such that each side of each flooringpanel is joined to only one adjacent flooring panel, it should beappreciated that individual flooring panels within a flooring system mayvary in size (e.g., width and/or length) and shape (e.g., rectangular,square, triangular, hexagonal, etc.). In one aspect of the presentinvention, individual flooring panels may have complementary shapescapable of being assembled similar to a puzzle or mosaic. Further, oneaspect of the present invention contemplates that sides of individualflooring panels may contact more than one adjacent flooring panel.

In accordance with the principles of the present invention, flooringpanels (i.e., planks) within a flooring system may be arranged such thatat least one side of each plank includes at least one sub-panel adjacentat least two other sub-panels. In another aspect of the presentinvention, each plank may include, either entirely or partially, atleast one partial sub-panel, as will be described in greater detailbelow.

In FIG. 13A, for example, partial sub-panel 134A of plank 130A may be acomplementary sub-panel with respect to neighboring partial sub-panel136B of plank 130B, adjacent plank 130A. With this arrangement, itappears that partial sub-panels 134A and 136B are one unitary panel.

Still referring to FIG. 13A, each of the planks 130A-F may comprise atleast three sub-panels wherein at least one of the sub-panels is aunitary sub-panel and at least two of the sub-panels are partialsub-panels. For example, 132A is a unitary sub-panel and 134A and 136Aare partial sub-panels.

In one aspect of the present invention, the unitary sub-panel 132A mayprovide a complete decorative motif. In another aspect of the presentinvention, the partial sub-panels 134A and 136A of a plank may provideseparated, incomplete decorative motifs. In one aspect of the presentinvention, neighboring partial sub-panels of adjacent planks may becomplementary to each other such that they provide a substantiallycomplete decorative motif and/or surface texture and appear as asubstantially continuous unitary panel. In one aspect of the presentinvention, complementary partial sub-panels may have complementarydecorative motifs and/or embossed surface textures. Accordingly, whencomplementary partial sub-panels of adjacent planks are properlyaligned, a substantially continuous (i.e., complete) decorative motifand/or embossed surface texture may be formed across neighboringcomplementary partial sub-panels. In one aspect of the presentinvention, sub-panels within a plank may or may not comprisesubstantially the same decorative motif and/or embossed surface texture.

FIG. 13B illustrates a schematic view of an exemplary plank 130 such asthat shown in FIG. 13A.

FIG. 13C illustrates a three dimensional view of the exemplary plank 130illustrated schematically in FIG. 13B. This three-dimensionalillustration of plank 130 is not drawn to scale, but rather exaggeratesfor purposes of clarity the relative geometries of the elements 132,134, 136, 138 a, 138 b, and 138 c in this aspect of the invention.

In one aspect of the present invention, portions of the perimetersurface may be recessed at locations where neighboring sub-panels arenot complementary. In another aspect of the present invention, portionsof the perimeter surface may be non-recessed at locations whereneighboring sub-panels are complementary. Referring to FIG. 13B,portions of the upper surface of the perimeter “P” of each of the planks130 indicated by reference numeral 138 a may be slightly recessedcompared to the major surface of each of the planks (see also FIG. 12B)to prevent premature wear of each of the planks. Further, portions ofthe upper surface of the perimeter of each of the planks 130 indicatedby reference numeral 138 b may be non-recessed and substantiallycoplanar with the major surface of the sub-panels. Recessing onlyportions of the perimeter surface of each of the planks at positionscorresponding to the decorative motifs and/or embossed surface texturesof partial sub-panels of a plank allows complementary partial sub-panelsto look as if they are a unitary sub-panel while not significantlydetracting from the overall durability of each of the planks. In yetanother aspect of the present invention, portions of the surface of eachplank may be recessed at locations where sub-panels of a plank areadjacent one another. Referring to FIG. 13B, portions of the uppersurface of each of the planks 130 indicated by reference numeral 138 cmay be slightly recessed compared to the major surface of each of theplanks (see also FIG. 12B) to provide a visual and textural effect thateach of the sub-panels of the plank are separate panels.

FIGS. 14A-14C illustrate an exemplary plank of a flooring system instill another aspect of the present invention.

Referring to FIGS. 14A-14C, similar to the plank shown in FIGS. 13A and13B, portions of the upper surface of the perimeter “P” of each of theplanks 130 indicated by reference numeral 138 a may be beveled toprevent premature wear of each of the planks. Further, portions uppersurface of the perimeter of each of the planks 130 indicated byreference numeral 138 b may not be beveled such that they aresubstantially coplanar with the major surface of the sub-panels.Beveling the perimeter surface of each of the planks at positionscorresponding to the decorative motifs and/or embossed surface texturesof partial sub-panels of a plank allows complementary partial sub-panelsto look as if they are a unitary sub-panel while not significantlydetracting from the overall durability of each of the planks. In yetanother aspect of the present invention, portions of the surface of eachplank may be provided with a groove at locations where sub-panels of aplank are adjacent to one another.

FIGS. 14B and 14C illustrate cross-sectional views of plank 130 takenacross lines I-I′ and II-II′, respectively. Referring to FIGS. 14B and14C, portions of the upper surface of each of the planks 130 indicatedby reference numeral 138 c may be beveled to form a groove. This groovemay also prevent premature wear of each of the planks. Thus, the grooveprovides a visual and textural effect that sub-panels of a plank areseparate. In one aspect of the present invention, the bevel at 138 c mayproduce a groove having a substantially V-shaped groove. It isappreciated, however, that the bevel may produce other groovetopographies (e.g., U-shaped grooves, etc.). In one aspect of thepresent invention, the beveling of each of the planks 130 at perimetersurface portion 138 a creates a groove between adjacent planks.Accordingly, the groove formed between adjacent ones of the planks, viabeveling at 138 a, has substantially the same width and topography asgrooves formed within the planks, via beveling at 138 c.

In addition, the visual and textural effect of the plank and itssub-panels is greatly improved by providing microbevels at perimetersurface portion 138 a of planks 130 to create a much smaller, and moreprecise groove between adjacent planks. In particular, these microbevelsare bevels with a depth or width of less than about 1 mm, for example,between 0.3 to 0.9 mm. Furthermore, the microbevel formed betweenadjacent ones of the planks, via microbeveling at 138 a, hassubstantially the same width and topography as grooves formed within theplanks, via beveling at 138 c. It is understood that within a singleplank, the microbevel along the perimeter edge of the plank is narrowerthan the microbevel between sub-panels in the interior region of theplank, so that when two planks are placed adjacent to each other, themicrobevel around the plank perimeter is indistinguishable from themicrobevel between sub-panels within a plank.

The motif and/or surface texture present at the recessed surface of theperimeter of each plank may or may not correspond to the motif/surfacetexture present at the main surface of a corresponding plank. Thus, asubstantially continuous motif and/or surface texture may or may not bepresent across the surfaces of the perimeter and the interior of anyindividual plank. Alignment marks or markings (not shown) can be used toself-align a decorative motif on the planks. In one aspect of thepresent invention, the embossed in-registration pattern may be a freeform or custom design. It is to be understood that substantially anyembossed-in-registration pattern and any decorative motif may berealized by applying the principles of the present invention. In oneaspect of the present invention, alignment of the planks may be donevisually upon joining them together. Accordingly, alignment of theplanks 130 may be performed using the decorative motif and/or embossedsurface texture of each of the planks.

While it is illustrated that the planks in FIGS. 13A, 13B, and 14A-14Care substantially rectangular, the principles of the present inventionallow the planks within the flooring system to have other shapes andsizes (e.g., geometric, freeform, etc.) or different or similardimensions such that the flooring panels may be assembled in a“mosaic”-type arrangement or other regular, semi-repetitious, or randomarrangement of panels. Further, while it is illustrated that each plankcomprises an identical sub-panel layout, the principles of the presentinvention allow the planks within the flooring system to have othersub-panel layouts (e.g., other sub-panel shapes, sizes, etc.) Theindividual planks within the flooring system may be cut from a boardsuch that joints between the flooring panels of the flooring system arenot visible. Further, the planks within the flooring system illustratedin FIGS. 13 and 14 may be joined together with or without glue. Stillfurther, while it has been discussed that the embossed surface textureis substantially aligned with an underlying decorative motif, it is tobe understood that substantially any embossed surface texture may beimparted to the planks of the present invention, regardless of theunderlying decorative motif. Still further, the decorative motifs and/orthe embossed surface texture of one plank may not be aligned or even beremotely similar in appearance and/or texture to decorative motifsand/or embossed surface textures of adjacent planks.

It will be apparent to those skilled in the art that variousmodifications and variations can be made in the present inventionwithout departing from the spirit or scope of the invention. Thus, it isintended that the present invention cover the modifications andvariations of this invention provided they come within the scope of theappended claims and their equivalents.

1. A plank, comprising a perimeter; a first upper surface defining afirst portion of the perimeter a second upper surface adjacent the firstupper surface and defining a second portion of the perimeter, whereinthe second upper surface is substantially non-coplanar with the firstupper surface; and a groove dividing the second upper surface into atleast two sub-surfaces, wherein the width of the groove is less thanabout 1 mm, wherein a lowermost surface portion of the first uppersurface is substantially coplanar with a lowermost surface portion ofthe groove.
 2. The plank according to claim 1, wherein at least aportion of the first portion of the perimeter is elevationally below atleast a portion of the second portion of the perimeter.
 3. The plankaccording to claim 1, wherein the first upper surface is substantiallyparallel to the second upper surface.
 4. The plank according to claim 1,wherein the first upper surface is oblique to the second upper surface.5. The plank according to claim 1, wherein the at least two sub-surfacesvisually depict separate motifs.
 6. The plank according to claim 1,wherein at least one of the at least two sub-surfaces is adjacent onlythe first upper surface and the groove.
 7. The plank according to claim1, wherein the groove is substantially V-shaped.
 8. The plank accordingto claim 1, wherein the groove comprises sidewalls substantiallyperpendicular to the second upper surface.
 9. The plank according toclaim 1, wherein the first upper surface and the groove visually depictsubstantially the same motif.
 10. The plank according to claim 1,further comprising at least one locking mechanism arranged elevationallybelow the first upper surface.
 11. The plank according to claim 10,wherein a portion of the at least one locking mechanism is hidden by thefirst upper surface.
 12. The plank according to claim 10, wherein aportion of the at least one locking mechanism is hidden by the secondupper surface.
 13. The plank according to claim 1, wherein the secondupper surface comprises a surface texture.
 14. The plank according toclaim 13, wherein the surface texture comprises at least one embosseddepression having a depth less than about 0.2 mm.
 15. The plankaccording to claim 13, wherein the surface texture is an embossedsurface texture.
 16. The plank according to claim 13, wherein thesurface texture is aligned with a decorative motif.
 17. The plankaccording to claim 13, wherein the surface texture is unaligned with adecorative motif.
 18. The plank according to claim 1, wherein the firstupper surface has a width about half the width of the groove.
 19. Theplank according to claim 1, wherein the width of the groove is betweenabout 0.3 and 0.9 mm.
 20. A plank, comprising a perimeter; a first uppersurface defining a first portion of the perimeter a second upper surfaceadjacent the first upper surface and defining a second portion of theperimeter, wherein the second upper surface is substantiallynon-coplanar with the first upper surface; and a groove dividing thesecond upper surface into at least two sub-surfaces, wherein the widthof the groove is less than about 1 mm, wherein the first upper surfaceis about 0.794 mm below the second upper surface.